Dye color control system

ABSTRACT

A method and apparatus for supplying dyes to a dyeing apparatus, dyes being selected to yield one of a group of colors. A plurality of tanks of dye is provided, and a circuit leads from each tank to a selected one of a pair of valves that may either direct the dye to the dyeing apparatus or direct the dye to be recirculated. The flow through each valve is metered so a particular rate of flow can be established. One group of the valves provides dye to the dyeing apparatus while another group of the valves recirculates dye to establish another color ready to be provided to the dyeing apparatus. The colors are defined in terms of the tanks and rate of flow from the tanks, so a large group of colors can be defined and stored in a computer, and the computer can control valve position and pump speed to control the color produced by the dyeing apparatus.

This application is a division of application Ser. No. 06/674,695, filedNov. 26, 1984, now U.S. Pat. No. 4,632,147.

INFORMATION DISCLOSURE STATEMENT

It is conventional in the dyeing of textiles and the like to provide adyeing apparatus wherein concentrated dyes are mixed together and placedinto water in the dyeing apparatus. The water dilutes the concentrateddye mixture and applies the diluted mixture to the fabric to be dyed.

While various colors are defined in terms of percentages of each of aplurality of dyes, these mixed colors must usually be prepared insufficient quantity for any given run since there tend to be variationsbetween dye batches. Also, it will be understood that a given color isplaced into the dyeing apparatus; and, to change colors, the system mustbe washed out to remove all traces of the previous color before a newcolor is placed into the apparatus. Changing of color is therefore timeconsuming and severely decreases an overall production rate.

While there are several forms of apparatus for metering two or moreliquids to provide a mix, such prior art apparatus has usually beencreated with the idea that a particular mix would be provided, and thesystem would be completely purged. Alternatively, the prior art systemshave been designed to provide no more than a few different mixes of thecomponents available. There has therefore been no means in the prior artfor providing a dyeing mix to a dyeing apparatus in order to achieve awide range of colors.

SUMMARY OF THE INVENTION

This invention relates to dye mixing for a dyeing apparatus, and is moreparticularly concerned with a continuous, automated system for providinga predetermined dye mix to achieve a plurality of predetermined colorsin a dyeing apparatus.

The present invention provides a plurality of dyes to be mixed invarious proportions for producing a wide variety of colors. Means areprovided for removing dye from each of a plurality of tanks andmeasuring the quantity of dye from each tank passing through the system.When two or more dyes are removed from two or more tanks, flow rates ofeach can be established to achieve the desired final mix.

Since textile dyes must generally be agitated to maintain consistency,the present invention provides for the establishment of the desiredflow, and means for continuously circulating the flow when the dye stuffis not actually provided to the dyeing apparatus. This allows the systemto be in readiness for substantially immediate feeding to the dyeingapparatus at the appropriate time.

In the preferred form of the invention, electronic data processing meansare utilized to store the colors in terms of flow rates of dyes so agiven color can be repeated quickly. Using the data processing system,along with the continuous circulating means, one color can be providedto the dyeing apparatus while another color is prepared but circulatingcontinuously and not fed to the dyeing apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention willbecome apparent from consideration of the following specification whentaken in conjunction with the accompanying drawings in which:

FIG. 1 is a block diagram showing the system of the present invention;

FIG. 2 is a block diagram showing the control arrangement of theelectronic data processing system; and,

FIG. 3 is a detailed schematic diagram showing a portion of the systemillustrated in FIG. 1 of the drawings.

DETAILED DESCRIPTION OF THE EMBODIMENT

Referring now more particularly to the drawings, and to that embodimentof the invention here presented by way of illustration, it will first beseen that there are six dye tanks designated 11-16. These six tanks aredivided into three groupings indicated as 1, 2 and 3. Thus, the tanks 11and 12 are designated as dye 1A and dye 1B, tanks 13 and 14 aredesignated as dyes 2A and 2B and tanks 16 and 16 are designated as dyes3A and 3B. Those skilled in the art will readily recognize that thesesix tanks, or three groups, can be utilized in many different ways.Also, additional groups may be added for some operations of the system.Nevertheless, by way of illustration, the embodiment here shown will bedescribed as utilizing the three groups and representing the threeprimary colors of red, yellow and blue. Further, dye number 1 will bereferred to as red, and tank 1A will have one dilution of red while tank1B has a different dilution of red. Using such an arrangement, it willbe understood that it will be very easy to produce numerous colors, bothlight shades and dark shades. Nevertheless, it must be realized thatthis arrangement is a matter of choice, since the tanks could havedarker colors, and a smaller amount of dye could be fed to achieve thesame result.

Considering now the dyes 1A and 1B, it will be seen that there is acontrol designated at 18 which both receives dye from, and returns dyeto, each of the tanks 11 and 12. Further, the control 18 delivers dye tometers 19 and 20. From the meters 19 and 20, the dye can pass throughvalves 21 and 22. The valves 21 and 22 are three-way valves so thematerial can either pass through the valve into the lines 24 and 25, orthe dye can pass through the valves 21 and 22 and into the lines 26 and28 by which the dye will be returned to the control 18.

From this brief description, it will be understood that dye can beremoved from the tanks 11 and 12, metered at 19 and 20, and passedthrough valves 21 and 22, through the lines 24 and 25 to theconventional dyeing apparatus 30. As will be discussed in more detailhereinafter, the control 18 will control the material from the tanks 11and 12 separately so material from (for example) tank 11 can be fedthrough one of the meters 19 or 20, and through one of the valves 21 or22 to be provided to the dyeing apparatus 30 while dye from the othertank can flow in a closed loop, returning from the valve 21 or 22through the line 26 or 28 so the proper flow can be established but thedye will not be provided to the dyeing apparatus 30.

The tanks 13 and 14 communicate with a control unit 18a, while the tanks15 and 16 communicate with a control unit designated at 18b. The threesystems are identical, so the description will not be repeated indetail. The same reference numerals are applied to the various parts,with a and b suffixes applied, as with the control unit 18a and 18b.

Looking now at FIG. 2 of the drawings, the operation of the systemshould be understandable. It will be seen that the dye bank management31 controls the dyes 1, 2 and 3. It will also be understood that thesecolors may be subdivided to achieve the complete arrangement shown inFIG. 1, or additional dyes can be added.

The formula management 32 includes the various color formulas storedwithin the data processing unit. A formula will define a particularcolor, and it will be understood that this color will be defined interms of a tank number, with a rate of delivery of the dye from thattank. By defining two or more dyes and their rates of delivery, it willbe understood that a given total composition will be defined. Thus, theformula management section 32 will be provided with the dye bank number34 and the rate of delivery 35. As a quality control means, the systemalso includes a calculation 36 of the percent concentration of each dyeso this can be monitored, and apparatus can be varied to achieve thedesired percent concentration.

Also in conjunction with formula management, there will be productiondata at 38. This is necessary to provide the color numbers in theappropriate order, and at the proper time.

Finally, there is a selected dye path at 39. Remembering the descriptionin conjunction with FIG. 1 of the drawings, a dye from the A tank or Btank can be fed through a meter 19 or 20. Thus, there is one dye pathfrom the tank 11, through the meter 19 and valve 21, and another pathfrom the tank 11 to the meter 20 and valve 22. Similarly, the due fromthe tank 12 can be fed through either the meter 19 or the meter 20. Inthe total formula management, the system will now which apparatus is inuse, and will select an available dye path.

The schedule management designated at 40 handles the scheduling of thepreviously described steps. The functions RUN A designated at 41 and RUNB designated at 42 indicate the two colors that can be completelyscheduled in the system as previously mentioned. One color can beprovided using three of the six valves 21 and 22, and another color canbe scheduled using the other valves. Thus, RUN A 41 can be executedusing, for example valves 21, 21a and 21b. RUN B 42 can simultaneouslybe set using valves 22, 22a and 22b with the dyes in all cases beingrecirculated through the lines 28, 28a and 28b. When RUN A is completed,RUN B can be almost immediately executed while a new RUN A is preparedwith a different color.

The next color is prepared through the function 44. A series of colorswill be entered into the system, and when the instruction for the nextcolor is given the system will retrieve the particular formula and beginthe scheduling including the selection of a particular dye path. Thereis of course a STOP function designated at 45.

Finally, the machine operations designated at 46 include the selectionof the dye path configuration as has been previously mentioned. Thepurge requirements designated at 48 will be discussed in more detailbelow, but generally indicates that dyes from two different tanks havebecome mixed, and the mixture is directed to waste to preventcontamination of the original dyes.

Other conventional operations are the RUN mode, STAND-BY mode, STOPPEDmode and NEW DATA mode. These modes are conventional and well understandby those skilled in the art, and no further description is thought to benecessary.

For a detailed understanding of the system of the present invention,attention is directed to FIG. 3 of the drawings. FIG. 3 is a detailedschematic showing the control unit 18 with the tanks 11 and 12, meters19 and 20 and valves 21 and 22. It will be understood that the othercontrol units would be constructed the same, so a description of thisone should suffice.

Considering the arrangement described above, it will be understood thatthe piping arrangement must allow liquid from the tank 11 to passthrough either the meter 19 or the meter 20, and liquid from the tank 12must be able to pass through either meter 19 or meter 20 and theassociated valve. Further, liquid from tank 11, regardless of the pathtaken, must be returned to the tank 11 and never to the tank 12. Thearrangement shown in FIG. 3 allows all these configurations.

Looking at the tank 11, it will be seen that the supply line 50 isdirected to a valve 51 which supplies a pump 52. The pump 52 has itsoutput connected to a branch line 54 that includes two valves 55 and 56.

Looking at the tank 12, it will be seen that there is a parallel lineincluding a supply pipe 60, a valve 61 feeding a pump 62, the output ofthe pump 62 being directed to a branch line 64 including valves 65 and66.

It will be seen that the output side of the valves 55 and 65 areconnected together, and are arranged to feed the meter 19. Similarly,the output sides of the valves 56 and 66 are connected together and arearranged to feed the meter 20. As a result, material fed from the tank11 through the supply line 50 will pass through the pump 52, and intothe branch line 54. At this point, the valve 55 can be opened to allowthe material to go to the meter 19, or the valve 56 can be opened toallow the material to go the meter 20. Similarly, material from the tank12 can pass through the supply line 60 and pump 62, and opening thevalve 65 will allow the material to go to the meter 19 while opening thevalve 66 will allow the material to go to the meter 20.

The return lines 26 and 28 have been previously mentioned, and it shouldbe noted that the lines 26 and 28 are connected to three-way valves 58and 68 respectively. The valve 58 can be positioned so that materialfrom the valve 21 will pass completely through the valve 58 and returnthe material through the line 59 to the tank 11. Simiarly, the valve 68can be positioned so that material passing through the return line 28will pass completely through the valve 68 and through the return line 69to be returned to the tank 12.

Since the valve 21 may be fed from the tank 12, the valve 58 can also bepositioned so that liquid returning to the valve 58 from the line 26will be diverted through the line 70 which is connected to the line 69to return the material to the tank 12. Similarly, the valve 68 can beplaced so that liquid from the return line 28 will be diverted throughthe line 71 which is connected to the return line 59 to return thematerial to the tank 11.

One additional setting on the valves 58 and 68 will allow the materialreturning from the lines 26 and 28 to go to waste, indicated at W. Thiswould be used for a purge, in the event there is contamination in thedye and it is not to be returned to the tank 11 or 12.

Those skilled in the art will realize that the supply of liquid to theconventional dyeing apparatus 30 will vary with the pressure under whichthe fluid is delivered. In order to maintain the desired pressures atall times, there are several pressure adjusting valves adjacent to thevalves 21 and 22. A valve 72 is placed between the meter 19 and thevalve 21 to adjust the pressure going to the valve 21. A valve 74 isplaced in the return line 26 to adjust the back pressure on the valve21. Finally, there is a valve 75 connected before the meter 19 and afterthe valve 74. The valve 75 therefore acts as a bypass to reduce thedelivery to the meter 19. Similarly, there are control valves associatedwith the valve 22. The valve 76 precedes the valve 22, the valve 78 isconnected in the return line 28, and the valve 79 is connected as abypass before the meter 20.

Following the pumps 52 and 62, there is an additional bypass valvelabeled 80 and 81. Opening these valves 80 and 81 will allow constantcirculation of the liquid in the tanks 11 and 12 to maintain homogeneityeven though the tank is not being actively used in the dyeing system.

With the above discussion in mind, it should be understood that aformula is defined in terms of particular dye tanks such as the tanks11-16. In conjunction with the particular tanks, a flow rate will beset, the flow rate being monitored by the meters such as the meters 19and 20. The color can be programmed into the system by selecting theparticular tanks and the particular meters, and establishing the desiredflows, but having the liquid from the final valves such as the valves 21and 22 simply return the liquid to the tank from whence it came. By thismeans, the entire system can be checked to assure that all desired flowrates have been established before opening the final valve to deliverthe material to the dyeing apparatus. Furthermore, two such colors canbe established, one using the valves 21, 21a and 21b while the otheruses the valves 22, 22a and 22b.

In operating an overall system, a large number of formulas will bestored in the formula management 32, the storage of a formula includingappropriate designations of tanks and flow rates. In scheduling aparticular operation, then, a plurality of formulas to be run will betemporarily stored in the schedule management 40. A first color will beset on RUN A 41 and a second color will be set on RUN B 42. Wheneverything is checked and ready for the first color, RUN A 41 will beexecuted and the appropriate valve such as the valves 21 and 22 will beopened to allow selected quantities of selected dyes to be delivered tothe dyeing machine 30. When the quantity of fabric to be dyed has beenrun through the dyeing apparatus 30, RUN B can be executed, and thecolor will change almost instantaneously.

At this point, it will be seen that the formula set on the RUN A is nolonger needed, so the next color can be called up, and the RUN A sectionof the apparatus can be reset for the next color to be run. When thefabric for the RUN B is completed, the apparatus will shift to the RUN Amode, again making an almost instantaneous change.

Though the various valves illustrated in the arrangement shown in FIG. 3can be operated by any desired means, it will be obvious that computercontrol is highly desirable. In using a computer, the computer will knowat all times which valves are open and which are closed, so the computerwill know which dye paths are in use, and which are available. Thisinformation allows selection of an unused dye path each time a differentcolor is to be set up into the system. This information dye to the tankfrom whence it came to prevent cross-contamination of dyes.

It will of course be understood by those skilled in the art that theparticular embodiment here presented is by way of illustration only, andis meant to be in no way restrictive; therefore, numerous changes andmodifications may be made, and the full use of equivalents resorted to,without departing from the spirit or scope of the invention as definedin the appended claims.

What is claimed is:
 1. A method for providing a color to a dyeingapparatus wherein said color comprises a mixture of a plurality of dyes,said mixture being provided for use in said dyeing apparatus, saidmethod including the steps of feeding a first dye from a first tank,metering said first dye and establishing a rate of flow of said firstdye, feeding a seocnd dye from a second tank, metering said second dyeand establishing a rate of flow of said second dye, said rate of flow ofsaid first dye and said rate of flow of said second dye being such as toyield said color when said first dye and said second dye are mixed, andcausing said first dye and said second dye to flow to said dyeingapparatus, said method further including the steps of defining aplurality of colors in terms of said tanks and flow rates from saidtanks, selecting some of said plurality of colors and establishing asequence of said some of said plurality of colors, and subsequentlycarrying out said steps of feeding a first dye and feeding a second dyefor providing each color of said some of said plurality of colors insaid sequence.
 2. A method as claimed in claim 1, and including thesteps of feeding a third dye from a third tank, metering said third dyeand establishing a rate of flow of said third dye, feeding a fourth dyefrom a fourth tank, metering said fourth dye and establishing a rate offlow of said fourth dye, said rate of flow of said third dye and saidrate of flow of said fourth dye being such as to yield a second colorwhen said third dye and said fourth dye are mixed, and continuouslycirculating said third dye and said fourth dye at the established rateof flow while said first dye and said second dye flow to said dyeingapparatus.
 3. A method as claimed in claim 2, wherein said color andsaid second color comprise two colors of said some of said plurality ofcolors, and further including the steps of terminating the flow of saidfirst dye and said second dye to said dyeing apparatus, causing saidthird dye and said fourth dye to flow to said dyeing apparatus forproviding said second color, and establishing flows of dyes for formingthe next color in said sequence.